Method for forming a cavity and a component having a cavity
10840107 ยท 2020-11-17
Assignee
Inventors
- Simon Armbruster (Budapest, HU)
- Benjamin Steuer (Waldenbuch, DE)
- Stefan Pinter (Reutlingen, DE)
- Dietmar Haberer (Reutlingen, DE)
- Jochen Tomaschko (Gaufelden, DE)
Cpc classification
H01L21/4803
ELECTRICITY
H01L21/3083
ELECTRICITY
B81C1/00103
PERFORMING OPERATIONS; TRANSPORTING
B81C1/0042
PERFORMING OPERATIONS; TRANSPORTING
International classification
B81B1/00
PERFORMING OPERATIONS; TRANSPORTING
H01L21/48
ELECTRICITY
Abstract
A method for forming a cavity in a silicon substrate, a surface of the silicon substrate having a tilting angle relative to a first plane of the silicon substrate, and the first plane being a {111} plane of the silicon substrate, and situation of an etching mask on the surface of the silicon substrate. The etching mask has a retarding structure that protrudes into the mask opening, and a first etching projection region. All further edges of the mask opening outside the first etching projection region are situated essentially parallel to {111} planes of the silicon substrate. The method includes an anisotropic etching of the silicon substrate during a defined etching duration. An etching rate in the <111> directions of the silicon substrate is lower than in other spatial directions, and the first retarding structure is undercut in a first undercut direction going out from the first etching projection region.
Claims
1. A component, comprising: a silicon substrate that has a cavity, the cavity being on a surface of the silicon substrate and having a rectangular opening, a floor surface of the cavity being inclined by a tilting angle relative to the surface of the silicon substrate, the floor surface of the substrate being situated on a {111} plane of the silicon substrate, wherein the tilting angle is in a range between 1 and 40, wherein the silicon substrate has a through-opening that extends between the floor surface of the cavity and a rear side of the silicon substrate situated opposite the surface, wherein the through-opening produces a gap in the floor surface of the cavity, wherein the gap is situated approximately in a center of the floor surface, wherein an edge surface formed from the floor surface is situated around the gap.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS
(12) In the following description of the various specific embodiments, identical reference characters are used for identical elements or elements having identical function.
(13) Silicon substrate 1 can for example have monocrystalline silicon. In order to form cavity 100, silicon substrate 1 is provided in such a way that one of the {111} planes is inclined by tilting angle 7 relative to surface 3 of silicon substrate 1, and forms a first plane 5 of silicon substrate 1. This silicon substrate can be produced for example through oblique sawing. Tilting angle 7 can be for example in a range between 1 and 40. Preferably, it is between 5 and 20.
(14) Cavity 100 is produced by an anisotropic wet-chemical etching of silicon substrate 1. For the anisotropic etching, an etching solution is used in which an etching rate in some crystal directions of silicon substrate 1 is lower than in other crystal directions. Given the use of an etching solution that includes KOH or TMAH, the slowly etching crystal directions are for example the <111> directions. If the etching rate in the <111> directions is lower than in other spatial directions, as is assumed in the following description, then the {111} surfaces perpendicular to the <111> direction form during the etching. This is described in the article by Oosterbroek et al.
(15) In order to define the shape of cavity 100, before the etching an etching mask is situated on surface 3 of silicon substrate 1. Given the use of an etching solution containing KOH, the etching mask can for example contain SiO or SiN.
(16) As is also stated in the article by Oosterbroek et al., all edges of the etching mask that are not situated in a {111} plane of silicon substrate 1 are undercut until in each case a side surface has formed in a {111} plane. Because the section lines of surface 3 of silicon substrate 1 form in general a hexagonal structure with the {111} planes of silicon substrate 1, which are tangential to a rectangular mask opening, the rectangular opening 110 of cavity 100 cannot be produced using a rectangular mask opening.
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(18) When there is an anisotropic etching of silicon substrate 1 with test mask 500, first and second transverse edge 511, 512 of the test mask opening are not undercut, because these are situated in first {111} plane 501 or second {111} plane 502. In contrast, first longitudinal edge 515 of test mask opening 510 is undercut until third {111} plane 503 and fourth {111} plane 504 are exposed. Next to a rectangular opening in the region of test mask opening 510 there thus results a first undercut region 520 that forms, on surface 3 of silicon substrate 1, a triangular opening adjoining the rectangular opening in the region of test mask opening 510. This triangular opening is limited by first longitudinal edge 515 of test mask opening 510 and by a first undercut edge 525 and a second undercut edge 526. First undercut edge 525 and first longitudinal edge 515 enclose a first undercut angle 522, while second undercut edge 526 and first longitudinal edge 515 enclose a second undercut angle 524.
(19) The length of first undercut edge 525 and of second undercut edge 526, and the size of first undercut angle 522 and of second undercut angle 524, are a function of the position of the {111} planes, and thus of the size of tilting angle 7 of first plane 5 relative to surface 3 of silicon substrate 1. For small tilting angle 7, the triangle that limits first undercut region 520 on surface 3 of silicon substrate 1 can be assumed to be equilateral. Thus, first undercut angle 522 and second undercut angle 524 can also be assumed to be equal in size. For a tilting angle of 8, first undercut angle 522 and second undercut angle 524 can for example be approximately 32.
(20) On second longitudinal edge 516 of test mask opening 510, analogously a second undercut region 530 is formed that produces a further triangular opening in the surface of silicon substrate 1. The shape of second undercut region 530 can here correspond to a rotation of first undercut region 520 by 180. In particular, first undercut angle 522 and a third undercut angle 532, situated diagonally opposite the first undercut angle relative to test mask opening 510, can be equal in size. Likewise, second undercut angle 524 and a fourth undercut angle 533, situated diagonally opposite the second undercut angle, can be equal in size. For small tilting angles 7, the opening of second undercut region 530 can also be assumed to be equilateral.
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(22) Through a targeted undercutting of first retarding structure 220 and of second retarding structure 240, cavity 100 shown in
(23) First etching mask 200 is situated on surface 3 of silicon substrate 1 in such a way that first transverse edge 211 is situated in first plane 5 intersecting surface 3 at tilting angle 7. In this way, second transverse edge 212, also running parallel to first transverse edge 211, is situated in one of the {111} planes of silicon substrate 1.
(24) First retarding structure 220 has a triangular base structure 260. A first side 261 of triangular base structure 260 connects an end of first transverse edge 211 to an end of second transverse edge 212, and is oriented at a right angle to first transverse edge 211 and to second transverse edge 212. A second side 262 and a third side 263 of the triangular base structure are situated respectively at an end of first side 261, and form, with first side 261, a respective first base angle 264 or second base angle 265. The second and the third side of base structure 260 are each situated essentially parallel to {111} planes of silicon substrate 1.
(25) The shape of triangular base structure 260 can for example be determined by carrying out a test etching using test mask 500 shown in
(26) First retarding structure 220 has a trapezoidal first delaying structure 270. First delaying structure 270 is connected to triangular base structure 260, and is situated at a first corner 267, situated opposite first side 261, of triangular base structure 260. First delaying structure 270 has a first edge 271 and a second edge 272 that run parallel to second side 262 of triangular base structure 260. A third edge 273 of first delaying structure 270 stands perpendicular to first and second transverse edge 211, 212 of mask opening 210. A fourth edge 274 of first delaying structure 270 is connected to third side 263 of triangular base structure 260.
(27) With the exception of third edge 273 of first delaying structure 270, all edges of first retarding structure 220 are thus configured essentially parallel to {111} planes of silicon substrate 1, and are not undercut during the anisotropic etching of silicon substrate 1. Only third edge 273 of first delaying structure 270 is undercut, and forms a first etched edge 223 of a first etching projection region 222. A link 275 of first delaying structure 270 in a first undercut direction 8 is dimensioned such that third edge 273 is situated at a distance, by an etching retardation 221, from first side 261 of base structure 260.
(28) Second retarding structure 240 is fashioned analogously to first retarding structure 220, and is situated at the respectively other ends of first and second transverse edge 211, 212. As second undercut region 530 of test mask 500 can correspond to rotated first undercut region 520, second retarding structure 240 can be obtained by rotating first retarding structure 220 by 180. In particular, second retarding structure 240 has a further triangular base structure 280 and a second delaying structure 276. As in first retarding structure 220, all edges of second retarding structure 240, with the exception of a longitudinal edge 277 of second delaying structure 276, are situated essentially parallel to {111} planes of silicon substrate 1. Longitudinal edge 277 thus forms a second etched edge 243 of a second etching projection region 242.
(29) Through anisotropic etching, cavity 100 shown in
(30) Overall, in this way there results the essentially rectangular opening 110 of cavity 100 shown in
(31) During the anisotropic etching, cavity 100 is formed through a stepped etching progression that proceeds from first transverse edge 211 in the direction of second transverse edge 212 until the {111} plane running through second transverse edge 112 has been reached. In this plane, there forms further floor surface 117 of cavity 100. As the etching duration increases, an ever-deepening cavity forms until first plane 5 of silicon substrate 1, running in one of the {111} planes, is completely exposed and forms floor surface 115 of cavity 100.
(32) For the complete formation of floor surface 115, it must be ensured that first and second retarding structure 220, 240 are undercut up to first and second longitudinal edge 113, 114 of cavity 100 at the earliest when floor surface 115 of cavity 100 is completely exposed. This is ensured through a suitable selection of etching retardation 221, defined by the length of delaying structures 270, 276 in undercut directions 8, 9. In order to ascertain the etching duration required to form cavity 100, an etching rate in the depth direction (perpendicular to surface 3 of silicon substrate 1) is determined using test etchings. Alternatively, the etching rate in the depth direction can also be calculated from known etching rates in other directions, for example in the crystal directions of substrate 1. The etching duration is then determined from the etching rate in the depth direction and the desired overall depth of cavity 100. The necessary etching retardation 221 then results from the product of the etching duration and a lateral etching rate in undercut directions 8, 9.
(33) In order to avoid premature undercutting of triangular base structure 260 given manufacturing and orientation tolerances, it is advantageous to make first and second base angle 264, 265 each somewhat larger than the angle of intersection of a {111} plane with first side 261 of base structure 260. In this way, second side 262 and third side 263 of base structure 260 are minimally undercut at the beginning of the anisotropic etching, until the {111} planes, running somewhat inside triangular base structure 260, have formed.
(34) In
(35) In addition, second etching mask 201 has a further reinforcing structure 292 that, analogous to reinforcing structure 290, connects second etched edge 243 of second delaying structure 276 to second transverse edge 212 of second etching mask 201, and is also undercut until it stands free. Moreover, second etching mask 201 has additional reinforcing structures 294 for base structures 260, 280. Etching projection regions 222, 242 also include, in second etching mask 201, the edges of reinforcing structures 290, 292, 294.
(36) Reinforcing structures 290, 292, 294 prevent parts of retarding structures 220, 240 from detaching from second etching mask 201 after the undercutting has taken place.
(37) In order to ensure an undercutting of the edges of reinforcing structures 290, 292, 294, these do not have to be situated perpendicular to first and second transverse edge 211, 212 of mask opening 210. It is sufficient if they are not situated in {111} planes of silicon substrate 1. The edges of reinforcing structures 290, 292, 294 also do not have to be all situated in parallel, as shown in
(38) In
(39) In order to enable an undercutting of first prolonged delaying structure 400, a first edge 401 and a second edge 402 of first prolonged delaying structure 400 are not situated in {111} planes of silicon substrate 1. In particular, first base angle 264 and a first tilting angle 403 between first longitudinal edge 113 that is to be formed and first edge 401 of first prolonged delaying structure 400 are not equal in size. In third etching mask 202, first etching projection region 222 is then defined by first edge 401 and second edge 402 of first prolonged delaying structure 400. First edge 401 and second edge 402 do not have to be situated parallel to one another, as shown in
(40) The time duration required for a complete undercutting of first prolonged delaying structure 400 is determined by first tilting angle 403 and the width of first prolonged delaying structure 400. These have to be selected such that the time required for the overall undercutting of first retarding structure 220 is longer than the time required for the complete exposure of floor surface 115.
(41) For third etching mask 202, second retarding structure 240 has a second prolonged delaying structure 410. Second prolonged delaying structure 410 is fashioned analogously to first prolonged delaying structure 400, and has in particular a second tilting angle 413. First tilting angle 400 and second tilting angle 413 can be identical. Second etching projection region 242 is formed by a first edge 411 and a second edge 412 of second prolonged delaying structure 410.
(42) In
(43) A first retarding structure 300 of fourth etching mask 203 has a first segment 301, a second segment 302, and a third segment 303. First segment 301 includes a first oblong region 310, a first pointed region 320, as well as a first base triangle 330 and a second base triangle 335.
(44) First oblong region 310 has two side edges 313. Side edges 313 are situated parallel to transverse edges 211, 212 of mask opening 210. First oblong region 310 can for example be made rectangular, and first base triangle 306 and second base triangle 307 can for example be made as right triangles. First pointed region 320 is situated on a first side 311 of first oblong region 310. First longitudinal edge 113 of the cavity is fashioned on an oppositely situated second side 312 of first oblong region 310. Base triangles 330, 335 are situated such that respectively one of their sides prolongs second side 312 of first oblong region 310, and a further side is respectively adjacent to one of the side edges 313 of first oblong region 310.
(45) All sides of fourth etching mask 203 inside first segment 301 are essentially situated in {111} planes of silicon substrate 1. In particular, first pointed region 320, fashioned as a triangle, has, analogously to triangular base structure 260 of first etching mask 200, first base angle 264 and second base angle 265 on first side 311 of first oblong region 310. Here, first pointed region 320 is a triangle similar to triangular base structure 260 of first, second, and third etching mask 200, 201, 202. Likewise, a first base edge 331 of first base triangle 330 spans the first base angle 264 with first longitudinal edge 113 of cavity 100, later to be formed, and a second base edge 336 of second base triangle 335 spans second base angle 265 with first longitudinal edge 113.
(46) In the anisotropic etching, no undercutting takes place at all edges of first segment 301. Only a first point 321 of first pointed region 320 fashioned as a triangle acts as first etching projection region 222. Going out from there, first the first pointed region 320 and subsequently first oblong region 322 is undercut in undercut direction 8.
(47) In second segment 302 and in third segment 303, first retarding structure 300 of fourth etching mask 203 is formed analogously to first segment 301, and in each case has a second oblong region 340, or third oblong region 360, and a second pointed region 350, or third pointed region 370. Second pointed region 350 is situated on a first side 341 of second oblong region 340, while first longitudinal edge 113 is fashioned on a second side 342 of second oblong region 340. In second segment 302, first retarding structure 300 of fourth etching mask 203 is undercut analogously to first segment 301 in first undercut direction 8. A second point 351 of second pointed region 350 forms a third etching projection region 225. Going out from second point 351, first the second pointed region 350, and then second oblong region 340, is undercut in first undercut direction 8. Analogously, in third segment 303, first the third pointed region 370 and then third oblong region 360 are undercut in first undercut direction 8. The undercutting of the first, second, and third segment 301, 302, 303 here takes place approximately simultaneously, so that the first longitudinal edge 113 is formed after the elapsing of the etching duration. Here, the etching duration required for the complete formation of first longitudinal edge 113 can be controlled via the size of etching retardation 221, as described in connection with
(48) Because segments 301, 302, 303 of first retarding structure 300 of fourth etching mask 203 are each undercut independently of each other, disturbances in the etching process in one of the segments 301, 302, 303, which can be caused for example by detaching parts of fourth etching mask 203, have an effect on the waviness of first longitudinal edge 113 only in the part thereof adjoining the respective region. Thus, overall a low degree of residual waviness of first longitudinal edge 113 can be achieved. In this way, a cavity 100 can be produced whose opening 110 has an approximation that is as good as possible to an ideal rectangular shape. Fourth etching mask 203 can also have fewer or more than the depicted three segments 301, 302, 303. For a given length of first longitudinal edge 113, the width of oblong regions 310, 340, 360 is then to be adapted such that the overall first longitudinal edge is covered by first retarding structure 300 of fourth etching mask 203. The residual waviness of first longitudinal edge 113 can be less the more narrow oblong regions 310, 340, 360 are made. Correspondingly, narrow oblong regions 310, 340, 360 make it possible to produce a cavity 100 having an opening 110 that comes particularly close to the ideal rectangular shape.
(49) To form second longitudinal edge 114, a second retarding structure 305 is situated opposite fourth etching mask 203 of first retarding structure 300 of fourth etching mask 203. Here, second retarding structure 305 of fourth etching mask 203 is, analogous to first retarding structure 300 of fourth etching mask 203, divided into a plurality of segments each having a pointed region, an oblong region, and two base triangles. The oblong regions of first and second retarding structure 300, 305 of fourth etching mask 203 are situated offset to one another transverse to transverse edges 211, 212, so that segments 301, 302, 303 of first retarding structure 300 of fourth etching mask 203 are made so as to mesh with the segments of second retarding structure 305 of fourth etching mask 203. Second retarding structure 305 of fourth etching mask 203 can be produced by rotating first retarding structure 300 of fourth etching mask 203 by 180.
(50) The base triangles, such as first and second base triangle 330, 335, prevent the region of fourth etching mask 203 situated at first and second longitudinal edge 113, 114 from being prematurely undercut. This is achieved in that the base edges of the base triangles, such as the first and the second base edge 331, 336, are situated in {111} planes of silicon substrate 1. The base triangles of fourth etching mask 203 shown in
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(52) In addition to cavity 100, in the specific embodiment of
(53) Component 700 can for example be used as a bearer for an optical element, for example a planar optical element such as a mirror, a window, a filter, or an optical grid. Here, the optical element can lie on edge surface 118. Through-opening 120 enables an optical access to the optical element from rear side 4 of silicon substrate 1. Floor surface 115 of cavity 100, inclined by tilting angle 7, enables an inclined situation of the optical element relative to surface 3 of silicon substrate 1. If component 700 is made without through-opening 120, then an element can be situated in cavity 100 that does not have to be accessible from both sides, such as a mirror or an optical grid. Component 700 can also itself be used as an optical element for suitable spectral regions, for example as a prism for electromagnetic radiation in the infrared range.
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(55) Instead of first etching mask 200, second, third, or fourth etching mask 201, 202, 203 can also be used. Further etching mask 1200 is fashioned in the same manner as first, second, third, or fourth etching mask 200.
(56) Through-opening 120 is fashioned as described in connection with
(57) Through-opening 120 can for example be produced by a directed etching process, for example by reactive ion deep etching. For this purpose, a further one-sided etching mask, that can for example have a lacquer, can be applied on silicon substrate 1 with cavity 100. The etching mask is opened corresponding to through-opening 120.
(58) Alternatively, through-opening 120 can be fashioned using a method as shown in the schematic sectional representation of
(59) In floor surface 115 of cavity 100 there is fashioned a first trench 122 that extends into silicon substrate 1 in the direction of further cavity 1115. Here, trench 122 does not break through floor surface 1115 of further cavity 1100. First trench 122 can for example be made in a closed annular shape, and can run along the contour of through-opening 120, which is still to be formed. First trench 122 can for example be produced using a directed etching process described in connection with
(60) From rear side 4 of silicon substrate 1, for example also using a directed etching process, a second trench 1122 is fashioned that does not break through floor surface 115 of cavity 100. This trench can be formed on the rear side 4 of silicon substrate 1, or, if, as shown, silicon substrate 1 has further cavity 1100, in floor surface 1115 of this cavity. Further trench 1122 extends into silicon substrate 1 in the direction of floor surface 115 of cavity 100. Second trench 1122 is offset relative to first trench 122. For example, it can be offset outwardly or inwardly relative to through-opening 120 to be formed.
(61) First trench 122 and second trench 1122 are each made so deep that a floor 1123 of second trench 1122 is situated closer to floor surface 115 of cavity 100 than a floor 123 of first trench 122. Through-opening 120 can then be produced by etching away a part 2 of silicon substrate 1 that is situated between first trench 122 and second trench 1122. For this purpose, for example an anisotropic etching process can be used, such as a brief immersion in a KOH solution.
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